Method for forming outerlayer on a curved surface

ABSTRACT

A method for forming an outside layer on a curved surface and a kit for the same purpose is disclosed. The method here is achieved by the following steps: (a) providing an assembling kit containing a first set and a second set; (b) assembling the first set and a second set together to form an outside layer on the curved surface. The first set of the assembling kit consists of a central hexagon and three pentagons. The second set consists of one binding hexagon and two peripheral hexagons. As the first set and the second set is combined together, only one respective edge of the central hexagon abuts one corresponding edge of each binding hexagon.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is related to a method for forming an outside layer on a curved surface, and especially, relates to a method for forming an outside layer on ball-shaped surface.

2. Description of Related Art

So far, the most popular methods for forming a pattern on a curved surface such as a ball-surface can be the piece-up method or integral molding method. The direct-fixing method is achieved by preparing a well-printed outside layer which is big enough to cover the curved surface. Then the outside layer is fixed to cover the target curved surface. However, the method illustrated above easily generates wrinkles on the surface of the fixed outside layer or the edges thereof. Therefore, the appearance of the achieved outside layer on the curved surface is unattractive. Most important of all, the outside layer on the curved surface causes an unrealistic appearance, especially for some patterns, pictures, or photos. On the other hand, the conventional piece-up method of assembling small pieces of pads together is costly since it is labor intensive and slow. Moreover, as the curved surface is small, the method is not practical. In addition, gaps inevitably occur between the pieces used in the traditional piece-up method and they cause further difficulties during the assembling.

Taking assembly of a soccer ball pattern on a ball surface for example, a pad made of ten hexagons and six pentagons (see FIG. 1) are commonly prepared in the traditional piece-up method. The pad shown FIG. 1 is used for covering a hemi-spherical surface and is cut into several single pentagons and hexagons before assembling. Then all the pentagons and hexagons are adhered or stitched to the hemi-spherical surface individually by labor. Therefore, the traditional piece-up method needs considerable skilled labors, which furthermore is time-consuming. In the traditional piece-up method, the gaps between the pentagons and the hexagon cannot be well controlled since too many single pads need to be adhered or stitched. Additionally, the assembly is difficult as the size of the curved surface is small since the angle or the side length of the pentagons or the hexagons cannot be well cut. In most cases, some differences between pentagons (or hexagons) are generated naturally when particularly small curved surfaces are involved.

Imperfect pictures or the patterns formed through the direct-fixing method are particularly hard to be improved after the big sheet of cover of pictures or patterns is adhered to the curved surface. In other words, it is very difficult to prevent or remove the wrinkles occurring on the cover sheet, especially for the adhesion or stitching of the sheet on a surface with high degree of curvature (for example, the ball surface).

Therefore, it is desirable to provide an improved method to mitigate the aforementioned problems.

SUMMARY OF THE INVENTION

The method of the present invention relates to a method for forming an outer layer on curved surface, and which can facilitate the assembly, reduce wrinkling, reduce variations between gaps, save the time in assembly of appropriate products, and reduce the cost of products. The present invention further relates to a kit for forming an outside layer on a curved surface. This kit will facilitate the assembling, reduce the quantity of wrinkles, reduce the variations between gaps, save time in assembly of products made using this method, and reduce the cost for assembly of such products.

To achieve the purpose above, the method for forming an outside layer on a curved surface of the present invention comprises the following steps: (A) providing a substrate having a curved surface, a first combining member consisting of a central hexagon and three pentagons, and three second combining members consisting of a binding hexagon and two peripheral hexagons; and (B) combining and fixing the first combining member, and the second combining members on the curved surface of the substrate. Among the first combining member and the second combining member, any two sides of two different pentagons of the same first combining member are not next to each other. In addition, one side of each pentagon is next to a respective side of the central hexagon of the first combining member or the central hexagon of the first combining member is next to one side of the pentagon. Moreover, each binding hexagon is next to a respective side of the peripheral hexagon of the second combining member, and any two sides of the two different peripheral hexagons of the same second combining member are not next to each other. Furthermore, when the first combining member, and the second combining member are combined together on the curved surface, at least one side of the central hexagon of the first combining member is next to one side of the binding hexagon of the second combining member.

In general, after the first combining member and the second combing member is assembled together, protrusions, or kinks happen on the edge of the first combining member and the second combing member. Hence, the method of the present invention can optionally further comprise a step of (C) making the first edge of the first combining member and the second edge of the second combining member comply with the third edge of the curved surface after the first combining member and the second combining member are fixed on the curved surface. Step (C) is carried out after step (B) is performed in the method of the present invention. The first edge of the first combining member and the second edge of the second combining member can be made to comply with the third edge of the curved surface through any conventional process in step (C). Preferably, the first edge of the first combining member and the second edge of the second combining member are cut or folded along the third edge of the curved surface.

The kit of the present invention includes: a first combining member having a central hexagon and three pentagons; three second combining members. Each second combining member has a binding hexagon and two peripheral hexagons. Among them, any two sides of two different pentagons of the same first combining member are not next to each other. Furthermore, one side of each pentagon is next to one side of the central hexagon of the first combining member or the central hexagon of the first combining member is next to one side of the pentagon. Moreover, each binding hexagon is next to one side of the peripheral hexagon of the second combining member. Any two sides of the two different peripheral hexagons of the same second combining member are not next to each other.

The hexagons (for example, the central hexagons, the binding hexagon, and the peripheral hexagons) of the kit of the present invention or those of the method of the present invention can be any conventional hexagons. Preferably, each angle between any two neighboring sides of the same hexagon in the first combining member or in the second combining member has the same angle. In other words, the shape of the hexagons of the present invention is preferred to be the same. More preferably, each side of each hexagon in the first combining member or in the second combining member has the same length. In other words, the sizes of the hexagon in the first combining member or in the second combining member are more preferable to be the same. Likewise, the pentagons of the kit of the present invention or those of the method of the present invention can be any conventional pentagons. Preferably, each side of the same pentagon in the first combining member has the same length. In other words, the pentagons of the present invention are preferred to be in the same shape. More preferably, each side of all pentagons in the first combining member has the same length. In other words, the pentagons of the present invention are more preferred to be of the same size. The patterns or the colors on the surface of the pentagons, the patterns or the colors on the surface of the central hexagons of the first combining member, the patterns or the colors on the surface of the binding hexagon, and the patterns or the colors on the surface of the peripheral hexagons can be the same or different. Preferably, the patterns or the colors on the surface of the pentagons, the patterns or the colors on the surface of the central hexagons of the first combining member, the patterns or the colors on the surface of the binding hexagon, and the patterns or the colors on the surface of the peripheral hexagons are different.

The curved surface suitable for the kit of the present invention or the method of the present invention can be any conventional curved surface. Preferably, the curved surface is an irregular curved surface, or the surface of a sphere or a hemi-sphere.

Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a pad for constructing a soccer ball in the prior art.

FIG. 2A is a view of the first combining member of the kit of the present invention.

FIG. 2B is a view of the second combining member of the kit of the present invention.

FIG. 2C is a view of the assembling of the first combining member and three second combining members of the kit of the first embodiment of the present invention.

FIG. 3 is a side view of an assembled sphere produced from the kit of the second embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIG. 2A, a first combining member 10 of the present invention is shown. The first combining member 10 of the present invention comprises a central hexagon 11 and three pentagons 12, 13, 14. As shown in FIG. 2A, one side of each pentagon 12, 13, 14 connects to a respective side of the central hexagon 11 in an alternating manner. That is, the central hexagon 11 is among the three pentagons 12, 13, 14, which are regularly separate from each other. With reference to FIG. 2B, a second combining member 20 of the present invention is shown. The second combining member 20 of the present invention comprises a binding hexagon 21 connectedly fitted between two peripheral hexagons 22, 23. The binding hexagon may be described as having an upper half and a lower half, each half having three faces, sequentially A, B and C. As shown in FIG. 2B, one side of each of the peripheral hexagons 22, 23 respectively contacts faces A and C, such that the peripheral hexagons are separate from each other. Referring to FIG. 2C, an assembly of the first combining member and three second combining members of the kit of the first embodiment of the present invention is shown. As the elements of the kit of the present invention are assembled, one of first combining members 10 and three of the second combining members 20, 30, 40 are arranged on a curved surface (not shown in FIG. 2C) through adhesion or stitching. One side of the binding hexagon 21 which is not next to the peripheral hexagon 22 of the second combining member 20 is arranged to be next to the available side of the central hexagon 11 of the first combining member 11. Moreover, one available side of the peripheral hexagon 22 of the second combining member 20 is next to a corresponding available side of the pentagon 12 of the first combining member 10. Likewise, one available side of the peripheral hexagon 23 of the second combining member 20 is next to a corresponding available side of the pentagon 13 of the first combining member 10. One available side of the binding hexagon 31 of the second combining member 20 is next to a corresponding available side of the central hexagon 11 of the first combining member 10. One available side of the binding hexagon 41 of the second combining member 20 is next to a corresponding available side of the central hexagon 11 of the first combining member 10. Furthermore, one of the available sides of the peripheral hexagon 32 of the second combining member 20 is next to a corresponding available side of the pentagon 13 of the second combining member 10. Similarly, one of the available sides of the peripheral hexagon 33 of the second combining member 20 is next to a corresponding available side of the pentagon 14 of the second combining member 10. One of the available sides of the peripheral hexagon 42 of the second combining member 20 is next to a corresponding available side of the pentagon 12 of the second combining member 10. One of the available sides of the peripheral hexagon 43 of the second combining member 20 is next to a corresponding available side of the pentagon 14 of the second combining member 10.

As the assembly progresses, the binding hexagon 21 of the second combining member 20 will be located between the pentagons 12, 13 of the first combining member 10. The binding hexagon 31 of the second combining member 30 will be located between the pentagons 13, 14 of the first combining member 10. The binding hexagon 41 of the second combining member 20 will be located between the pentagons 12, 14 of the first combining member 10.

FIG. 3 shows a complete assembly of the kit of the second embodiment of the present invention on a ball surface. The Y-shaped line 100 in FIG. 3 shows the location of the first combining member of the present invention after the kit is assembled. The central hexagon 11, the pentagons 12, 13, 14 of the first combining member can be found on the surface of the ball in FIG. 3 easily. The other three bent lines 200, 300, 400 show the location of the second combining member of the present invention after the kit is assembled. As shown in FIG. 3, the binding hexagon 21 of the second combining member is located between the pentagons 12, 13 of the first combining member. The binding hexagon 31 of the second combining member is located between the pentagons 13, 14 of the first combining member. The binding hexagon 41 of the second combining member is located between the pentagons 12, 14 of the first combining member.

Since an integrated set of pads such as the first combining member and the second combining member is used, the labor and the time required for assembling can be obviously reduced relative to the prior art. Moreover, the differences of the gaps between the sides of the pentagons or the hexagons can be reduced since fewer gaps exist.

Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. 

1. A method for forming an outside layer on a curved surface, comprising following steps: (A) providing a substrate having a curved surface with at least one edge, a first combining member consisting of a central hexagon and three pentagons, and three second combining members consisting of a binding hexagon and two peripheral hexagons; wherein any two sides of two different pentagons of the same first combining member are not next to each other, one side of each pentagon is next to a respective side of the central hexagon of the first combining member or the central hexagon of the first combining member is next to a respective side of the pentagon; each binding hexagon is next to one side of the peripheral hexagon of the second combining member, and any two sides of the two different peripheral hexagons of the same second combining member are not next to each other; and (B) combining and fixing the first combining member, and the second combining member on the curved surface of the substrate; wherein at least one side of the central hexagon of the first combining member is next to one side of the binding hexagon of the second combining member.
 2. The method as claimed in claim 1, further comprising a step (C) making a first edge of the first combining member and a second edge of the second combining member comply with a third edge of the curved surface after the first combining member and the second combining member is fixed on the curved surface.
 3. The method as claimed in claim 2, wherein the first combining member or the second combining member is folded to make the first edge of the first combining member or the second edge of the second combining member comply with the third edge of the curved surface in step (C).
 4. The method as claimed in claim 2, wherein the first combining member or the second combining member is cut to make the first edge of the first combining member or the second edge of the second combining member comply with the third edge of the curved surface in step (C).
 5. The method as claimed in claim 1, wherein each angle between any two neighboring sides of the same hexagon in the first combining member or in the second combining member has the same angle.
 6. The method as claimed in claim 1, wherein each side of each hexagon in the first combining member or in the second combining member has the same length.
 7. The method as claimed in claim 1, wherein each side of the same pentagon in the first combining member has the same length.
 8. The method as claimed in claim 1, wherein each side of all pentagons in the first combining member has the same length.
 9. The method as claimed in claim 1, wherein patterns on surfaces of the pentagons, patterns on surfaces of the central hexagons of the first combining member, patterns on surfaces of the binding hexagon, and the patterns on the surfaces of the peripheral hexagons are different from each other in appearance.
 10. A kit for forming an outside layer on a curved surface, comprising: a first combining member having a central hexagon and three pentagons; three second combining members having a binding hexagon and two peripheral hexagons; wherein any two sides of two different pentagons of the same first combining member are not next to each other, one side of each pentagon is next to a respective side of the central hexagon of the first combining member or the central hexagon of the first combining member is next to a respective of the pentagon, each binding hexagon is next to one side of the peripheral hexagon of the second combining member, and any two sides of the two different peripheral hexagons of the same second combining member are not next to each other.
 11. The kit as claimed in claim 10, further comprising a substrate having a curved surface with at least one edge.
 12. The kit as claimed in claim 11, wherein the first combining member and the second combining member is fixed on the substrate, and at least one side of the central hexagon of the first combining member is next to one side of the binding hexagon of the second combining member.
 13. The kit as claimed in claim 10, wherein each angle between any two neighboring sides of the same hexagon in the first combining member or in the second combining member has the same angle.
 14. The kit as claimed in claim 10, wherein each side of each hexagon in the first combining member or in the second combining member has the same length.
 15. The kit as claimed in claim 10, wherein each side of the same pentagon in the first combining member has the same length.
 16. The kit as claimed in claim 10, wherein each side of all pentagons in the first combining member has the same length.
 17. The kit as claimed in claim 10, wherein patterns on surfaces of the pentagons, patterns on surfaces of the central hexagons of the first combining member, patterns on surfaces of the binding hexagon, and the patterns on the surfaces of the peripheral hexagons are different from each other in wherein patterns on surfaces of the pentagons, patterns on surfaces of the central hexagons of the first combining member, patterns on surfaces of the binding hexagon, and the patterns on the surfaces of the peripheral hexagons are different from each other in appearance. 